Codes used to identify States party to the PCT on the front pages of pamphlets publishing international applications under the PCT.

AT Austria GB United Kingdom MR Mauritania

AU Australia GE Georgia MW Malawi

BB Barbados GN Guinea NE Niger

BE Belgium GR Greece NL Netherlands

BF Burkina Faso HI) Hungary NO Norway

BG Bulgaria IE Ireland NZ New Zealand

Bj Benin IT Italy PL Poland

BR Brazil P Japan PT Portugal

BY Belarus KE Kenya RO Romania

CA Canada KG Kyrgystan RU Russian Federation

CF Central African Republic KP Democratic People's Republic SD Sudan

CG Congo of Korea SE Sweden

CH Switzerland KR Republic of Korea SI Slovenia

CI Cβte d'lvoirc KZ Kazakhstan SK Slovakia

CM Cameroon LI Liechtenstein SN Senegal

CN China LK Sπ Lanka TD Chad

CS Czechoslovakia LU Luxembourg TG Togo

CZ Czech Republic LV Latvia TJ Tajikistan

DE Germany MC Monaco TT Tπnidad and Tobago

DK Denmark MD Republic of Moldova UA Ukraine

ES Spain MG Madagascar US United States of America

FI Finland ML Mali υz Uzbekistan

FR France MN Mongolia VN Viet Nam

GA Gabon

1 THERMAL ENERGY STORAGE FOR A VEHICLE COMPARTMENT

Technical Field

This invention relates to the storage and recovery of heating and cooling capacity in a thermal energy storage system. It is disclosed in the context of a thermal energy storage system including at least one thermal storage apparatus configured to be incorporated into the heating and cooling system of a vehicle or the like.

Background of the Invention

Use of heating and cooling systems for vehicular applications is common and well established to maintain a comfortable environment within the vehicle while the vehicle engine is operating. When the occupants of the vehicle stop driving and rest in the vehicle, the interior space in the vehicle can become very uncomfortable due to the air temperature within the vehicle increasing or decreasing. In most vehicles, the heating and cooling system maintains comfort levels within the vehicle only during engine operation. These heating and cooling systems do not provide space conditioning to the interior of the vehicle when the engine is turned off. Phase change materials ("PCMs") store heat during phase transition, typically liquid/solid phase transitions. For example, water, paraffins, alcohol, salts and salt hydrates have notably high energy densities over temperature ranges of practical significance. A large amount of thermal energy can be stored as latent heat of fusion during the melting of an appropriate PCM. The stored heat can then be extracted from the liquid PCM by cooling it until it crystallizes. Thermal energy can also be stored as sensible heat in PCMs.

Various attempts have been made to incorporate PCMs into heating and air conditioning systems, including heat pump systems, solar collection systems, and more conventional heating and air conditioning systems. For example, U.S. Patent No. 5,054,540 to Carr describes a cool storage reservoir positioned in the air duct of a vehicle or the like. A plurality of elongated sealed containers are positioned in the cool storage reservoir, each of the sealed containers being filled with a gas/water medium capable of forming a gas hydrate. U.S. Patent No.

5,277,038 to Carr also implements a thermal storage system into a vehicle using gas hydrates.

Gas hydrates, however, may possess a variety of disadvantages. Gas hydrates suffer from the development of significant pressures during decomposition and may be subject to excessive supercooling. They may also require specific devices to initiate nucleation. Another disadvantage of the 5,277,038 patent is that the vehicle's air distribution system is required to discharge the stored thermal energy. The vehicle air distribution system has a powerful blower which drains power out of the batteries very fast. Further, the 5,277,038 patent discloses storing high and low temperature thermal energy of the same temperature. This does not permit the system of the 5,277,038 patent to provide comfortable thermal conditioning of a vehicle interior. In addition, the system disclosed in the 5,277,038 patent is not compatible with electric powered vehicles (EV) which don't have vehicle heating and cooling systems. Another example is the "heat battery" designed to provide "instant" heating to a vehicle cabin. (Automotive Engineering, Vol. 100, No. 2, February, 1992). The core of the heat battery includes a series of flat, sheet metal PCM envelopes in spaced-apart relationship. The heat battery and an electric coolant pump are installed in a coolant

line running from the engine to the cabin heater, forming a closed circuit capable of very rapidly heating the cabin when the engine is turned on.

While such a design possesses certain advantages in typical passenger vehicle applications, there remains a need for thermal storage system designs which can be operated more flexibly. For example, there remains a particular need for a thermal storage system which can provide space conditioning for several hours to an enclosed when the engine is off.

Disclosure of the Invention

According to an aspect of the invention, a thermal energy storage system is operable in at least one of a heating mode and a cooling mode for maintaining a temperature in a vehicle compartment. Each mode includes a thermal charging cycle and a thermal discharging cycle. The thermal energy storage system communicates with at least one of a vehicle air conditioning system including a compressor and a vehicle coolant system including a heating source. The system comprises at least one thermal storage apparatus configured to house thermal energy storage material that stores thermal energy. The at least one thermal storage apparatus is connected to at least one of the air conditioning system and the coolant system so that at least one of a refrigerant and coolant flows through the thermal storage apparatus in heat transfer relationship with the thermal energy storage material. The system further comprises a transfer device and a transfer loop circulating a transfer medium between the at least one thermal storage apparatus and the transfer device. The transfer device includes a transfer coil connected to the transfer loop and a fan means for creating airflow across the transfer coil so that thermal energy stored in the thermal storage apparatus and transferred to the transfer

device by the transfer medium can be discharged into the vehicle compartment by exchanging thermal energy in the transfer medium contained in the transfer coil with the airflow. According to another aspect of the invention, a thermal energy system communicates with a coolant system and an air conditioning system. The coolant system includes a vehicle component to be cooled. The thermal energy system has cooling and heating charging cycles and cooling and heating discharging cycles. The thermal energy system comprises at least one thermal storage apparatus including a thermal energy storage material that stores thermal energy. A connection is provided between the thermal storage apparatus and the air conditioning system for circulating a refrigerant from the air conditioning system in heat exchange relationship with the thermal energy storage material during the cooling charging cycle. A connection is provided between the thermal storage apparatus and the coolant system for circulating a coolant from the coolant system in heat exchange relationship with the thermal energy storage material during the heating charging cycle. A controller controls the cooling charging cycle when the air conditioning system is operating and controls the heating charging cycle when a temperature of the vehicle component exceeds a predetermined temperature to transfer heat to the thermal energy storage material from the coolant to cool the vehicle component.

According to another aspect of the invention, a control system is provided for a thermal energy storage system that stores high and low temperature thermal energy for later discharge of the high and low temperature thermal energy into a confined space. The control system comprises a charging control circuit including first means movable between an open position and a closed position to control the flow of a low-temperature thermal energy medium to the

thermal energy storage system. Second means is movable between an open position and a closed position to control the flow of a high-temperature thermal energy medium to the thermal energy storage system. Means selectively controls the first and second means so that when the first means is in the open position the low temperature thermal energy medium flows through the thermal energy storage system and removes thermal energy from the thermal energy storage system, and when the second means is in an open position, the high temperature thermal energy medium flows through the thermal energy storage system and stores thermal energy in the thermal energy storage system. A thermostat detects temperature of a vehicle compartment so that when the temperature of the vehicle compartment reaches a preset temperature the thermal energy storage system discharges or stores thermal energy to maintain the temperature of the vehicle compartment.

According to another aspect of the invention a thermal energy system communicates with an air conditioning system and a coolant system to maintain a desired temperature in a vehicle compartment when one of the air conditioning system and coolant system is not capable of maintaining the desired temperature. The system comprises at least one thermal storage apparatus configured to have a thermal energy storage material that stores thermal energy. A connection is provided between the thermal storage apparatus and the air conditioning system for transferring a refrigerant from the air conditioning system to the thermal energy storage material. A connection is provided between the thermal storage apparatus and the coolant system for transferring a coolant from the coolant system to the thermal energy storage material. A fan adjacent to the thermal storage apparatus is configured to create a flow of air across the thermal storage apparatus to exchange thermal energy with the thermal energy storage

material and force the air into the vehicle compartment. A controller for operates the fan when one of the air conditioning system and coolant system is not capable of maintaining the desired temperature in the vehicle compartment to maintain such desired temperature.

According to another aspect of the invention, a thermal energy storage system is operable in at least one of a heating mode and a cooling mode for maintaining a temperature in a vehicle compartment. Each mode includes a thermal charging cycle and a thermal discharging cycle. The thermal energy storage system communicates with at least one of an air conditioning system including a compressor and a vehicle coolant system including a heating source. The thermal energy storage system comprises at least one thermal storage apparatus configured to house a thermal energy storage material that stores thermal energy. The at least one thermal storage apparatus is connected to at least one of the air conditioning system and the coolant system so that at least one of a refrigerant and a coolant flows through the thermal storage apparatus in heat transfer relationship with the thermal energy storage material. A fan is situated adjacent to the at least one thermal storage apparatus to create airflow across the thermal storage apparatus to exchange thermal energy with said thermal storage apparatus.

According to another aspect of the invention, thermal energy storage for a vehicle compartment comprises a first coolant loop comprising an engine and a heater coil with hot coolant supplied from the engine to the heater coil to provide positive thermal potential to the heater coil. A main air conditioning loop comprises a compressor, a condenser, a refrigerant receiver, a metering device, an evaporator, and first means to interrupt refrigerant flow to the evaporator and arranged to provide negative thermal potential to the evaporator. A vehicle air supply duct and

a blower has an inlet and an outlet. The heater coil and the evaporator are both located in the duct. Thermal energy storage means comprises an enclosed volume of thermal storage medium to store at least one of negative thermal potential and positive thermal potential. A refrigerant direct expansion coil delivers to the thermal storage medium negative thermal potential during a negative thermal potential charging cycle. A coolant coil delivers to the thermal storage medium positive thermal potential during a positive thermal potential charging cycle. A fan flows air to recover thermal potential from the thermal energy storage means to condition the air, and returns the conditioned air to the compartment during a thermal potential discharging cycle. A supplemental refrigerant loop comprises the refrigerant direct expansion coil in direct contact with the thermal storage medium to provide negative thermal potential to the thermal storage medium. The supplemental refrigerant loop is arranged in communication with the compressor, the condenser, and the refrigerant receiver of the main air conditioning loop to supply refrigerant flow to the direct expansion coil and with second means to interrupt this flow to the direct expansion coil. A second coolant loop provides hot coolant flow to the thermal storage medium. The second coolant loop comprises third means to interrupt hot coolant supply to the second coolant loop. The third means is arranged for fluid communication with the first coolant loop. An air conditioning first control means activates the compressor and the first means. A control system selects one of a first thermal storage charging mode to activate the compressor and the second means to store negative thermal potential, and a second thermal storage charging mode to activate the third means in the second coolant loop to store positive thermal potential, and to deactivate both the second and third means when not in a charging mode.

Brief Description of the Drawings

The detailed description particularly refers to the accompanying figures in which: Fig. 1 is a schematic view of an embodiment of a thermal energy storage system integrated into the space conditioning system of a vehicle in accordance with the present invention;

Fig. 2 is a schematic view of an embodiment of a thermal energy storage system integrated into the space conditioning system of a vehicle in accordance with the present invention;

Fig. 3 is an exploded perspective view of an embodiment of a thermal storage apparatus containing PCMs in accordance with the present invention for use in the thermal energy storage system shown in Fig. 2;

Fig. 4 is a schematic view of a charging control circuit showing the position of switches and relays when the vehicle interior is being cooled during engine operation and no coolant or refrigerant is being sent to the thermal energy storage system for thermal charging;

Fig. 5 is a schematic view of the charging control circuit of Fig. 4 showing the position of switches and relays to permit refrigerant flow into the thermal energy storage system to provide a low temperature thermal energy charging source;

Fig. 6 is a schematic view of the charging control circuit of Fig. 4 showing the position of switches and relays to permit coolant flow into the thermal energy storage system to provide a high temperature thermal energy charging source;

Fig. 7 is a schematic view of a charging control circuit showing the position of switches and relays when the vehicle interior is being cooled by the air conditioning system;

Fig. 8 is a schematic view of the charging control circuit of Fig. 7 showing the position of switches and relays when the air conditioning system is cooling the vehicle interior and refrigerant is flowing to the thermal energy storage system to provide a low temperature charging source;

Fig. 9 is a schematic view of the charging control circuit of Fig. 7 showing the position of relays and switches to permit refrigerant flow into the thermal energy storage system to provide a low temperature thermal energy charging source;

Fig. 10 is a schematic view of the charging control circuit of Fig. 7 showing the position of relays and switches to permit coolant flow into the thermal energy storage system to provide a high temperature thermal energy charging source; and

Fig. 11 is a schematic view of a discharging control circuit showing an ignition control circuit, a fan control circuit, and a thermostat control circuit.

Mode(s) for Carrying Out The Invention and Industrial Applicability

A thermal storage apparatus in accordance with the present invention is illustrated schematically in Fig. 1 integrated into a space conditioning circuit for a typical vehicle.

An embodiment of the present invention having a plumbed thermal energy storage system integrated into a space conditioning system 110 for a typical vehicle is illustrated schematically in Fig. 1. The space conditioning system 110 includes a thermal energy storage system 112 for storing thermal energy while the vehicle is operating and releasing the stored thermal energy into the vehicle when needed. Typically, the thermal energy storage

10 system 112 releases the stored thermal energy into the vehicle when the vehicle engine is not operating.

The space conditioning system 110 typically includes a coolant loop system 116 and an air conditioning refrigerant system 118. Typically, operation of the coolant loop system 116 and the air conditioning refrigerant system 118 requires that the vehicle engine is operating. The thermal energy storage system 112 heats and cools the vehicle interior when the vehicle engine is not operating.

The engine coolant loop system 116 includes a vehicle engine 120, a radiator 122, a heater coil 124, a thermostat 125, valve 158, and a closed coolant loop 126 transferring coolant in direction 127 between the engine 120, radiator 122, and heater coil 124. During operation of the vehicle engine 120, coolant passes through the engine 120 to prevent it from overheating. The coolant loop 126 transfers high temperature coolant exiting the engine 120 to the radiator 122 and the heating coil 124 to be cooled. When the vehicle operator wants to heat the interior of the vehicle, a vehicle blower 128 is turned on to blow air in direction 130 over the heating coil 124. The heating coil 124, located within the vehicle air duct system 142, exchanges heat with the forced air blown across its surface.

The heated air is then blown in direction 143 into the vehicle interior or in direction 149 toward the window defroster. A defrost control flap 151 situated in the vehicle air duct system 142 controls the amount of airflow directed toward the defroster. When the defrost control flap 151 is open, shown in dotted lines, airflow is directed toward the defroster. When the defrost control flap 151 is closed, shown in solid lines, airflow is directed toward the interior of the vehicle.

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The amount of airflow passing through the heater coil 124 is controlled by the position of an air control flap 137 situated in the vehicle air duct system 142. Airflow generated by vehicle blower 128 is allowed to pass through the heater coil 124 when the air control flap 137 is positioned up in a bypass duct 139 away from the heater coil as shown by the position of air control flap 137 in dotted lines. Airflow bypasses the heater coil 124 and flows through the bypass duct 139 when the air control flap 137 is positioned to cover the inlet of the heater coil 124 as shown by the position of air control flap 137 in solid lines.

The conventional air conditioning refrigerant system 118 includes a compressor 132, condenser 134, dryer 135, expansion valve 136, and evaporator coil 140. A refrigerant loop 144 circulates refrigerant in direction 145 through a closed loop between the compressor 132, condenser 134, dryer 135, expansion valve 136, and evaporator coil 140. The air conditioning refrigerant system 118 liquifies the refrigerant and then transfer the refrigerant to the evaporator coil 140. The vehicle blower 128 creates a forced airflow 130 across the evaporator coil 140 so that the airflow 130 and refrigerant can exchange heat to produce cool air and evaporate the refrigerant. This cooled airstrea is then blown in direction 143 into the interior of the vehicle through the vehicle air duct system 142.

More specifically, ambient airflow is drawn across the evaporator coil 140 where liquified refrigerant within the evaporator coil 140 provides cooling to the crossing air stream. The refrigerant expands and evaporates while absorbing the heat flux within the ambient air stream. The refrigerant, once expanded, is directed to the compressor 132 where it becomes a high temperature/high pressure gas vapor stream directed to the condenser 134.

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The condenser 134 desuperheats, liquifies, and subcools this high temperature refrigerant prior to its circulation back to the expansion valve 136 and evaporator coil 140 where it exchanges heat with the ambient air to provide cooling.

The engine coolant loop system 116 and air conditioning refrigerant system 118 require engine 120 operation. These systems 116, 118 do not heat or cool the interior of the vehicle when the engine 120 is not operating. It will be understood that in an electric powered vehicle (EV) there is no coolant loop 126 and that resistance coils are used for heating. Currently, an air conditioning system 118 is not practical to use in an EV vehicle because it uses too much energy. A thermal energy storage system 112 according to the present invention is provided to heat and/or cool the interior of a vehicle during interim engine 120 shutdown. The thermal energy storage system 112 operates in two cycles, a thermal charging cycle and a thermal discharging cycle. In the thermal charging cycle, the thermal energy storage system 112 acquires high temperature thermal energy from the engine coolant loop system 116 or low temperature thermal energy from the air conditioning refrigerant loop system 118. In the discharging cycle, the high or low temperature thermal energy stored in thermal energy storage system 112 is discharged into the interior of a vehicle. While the vehicle is in operation, either the heating effect obtained from a parallel or series connection to the engine coolant loop system 116 or the cooling effect obtained from the air conditioning refrigerant system 118 is circulated through the thermal energy storage system 112 for absorption. More specifically, the thermal energy storage system 112 may have high temperature PCMs primarily interacting with the coolant loop system 116 and low temperature PCMs primarily

13 interacting with the air conditioning refrigerant system 118. At engine 120 shutdown, the previously stored thermal energy is discharged to warm or cool the interior occupied spaces of the vehicle in an attempt to maintain a comfortable living and/or working environment. In addition, this thermal energy may be withdrawn from the thermal energy storage system 112 and circulated through the engine's coolant system 116 either prior to, or upon start-up, to warm up or to cool down the engine 120 and other vehicle components such as a vehicle battery.

The thermal energy storage system 112 is modular in design, consisting of all components necessary for operation. It only requires connection to the vehicle's coolant lines 126 and refrigerant lines 144. A forced airstream through a transfer device 154 is used to discharge the thermal energy stored in the high and low temperature PCMs into the interior of a vehicle. Because a forced airstream is used, the transfer device 154 should be located to allow unobstructed discharge airflow into the spaces of the vehicle to be conditioned. The location requirements of the transfer device 154 otherwise should only be in proximity to the associated coolant and refrigerant lines 126, 144 for ease of installation.

When a high and low temperature PCM is required, the preferred low temperature PCM is water and the preferred high temperature PCM is calcium chloride hexahydrate. In alternative embodiments of the present invention, the high temperature PCM can be a eutectic composition of magnesium chloride hexahydrate and magnesium nitrate hexahydrate.

The thermal energy storage system 112 includes a heat exchanger 146, expansion tank 148, pump 150, first thermal storage apparatus 152, and second thermal storage apparatus 154. A transfer loop 156 connects the heat exchanger 146, expansion tank 148, pump 150, and first and

14 second thermal storage apparatus 152, 154 to allow a transfer medium to travel in a closed loop between and through the components 146, 148, 150, 152, and 154 of the thermal energy storage system 112. The transfer medium is glycol. However antifreeze or any other fluid having a low freezing point and a high boiling point may be used as the transfer medium. The transfer loop 156 is an independent closed system and is dedicated to the thermal energy storage system 112 as a transfer medium circulation and energy transfer circuit.

Fig. 1 illustrates thermal energy storage system 112 which utilizes a single phase change material 155 for both high temperature and low temperature applications in a single thermal storage apparatus 152. The thermal storage apparatus 152 has a coolant loop side 364 that passes through the housing 153 in contact with the PCM 155.

The coolant loop side 364 includes a coolant coil. The transfer loop side 156 includes a glycol coil. The refrigerant loop side 168 includes a direct expansion coil. A coil configuration suitable for this embodiment of the present invention can be purchased from Astro Air of Jacksonville, Texas.

Engine coolant is circulated to thermal storage apparatus 152 through the coolant loop 126 with the opening of valve 160. The high temperature engine coolant circulates through the coolant loop side 364 located in direct contact with the single phase change material 155 housed in thermal storage apparatus 152. The coolant continues to circulate from the thermal storage apparatus 152 back into the engine's coolant system 116 to complete the coolant loop 126. The thermal energy absorbed into the phase change material 155 is retained until heating is required when the engine 120 is not operating.

During high temperature discharge, the transfer loop 156 containing the transfer medium is initiated by

15 pump 150. Pump 150 propels the transfer medium within the closed transfer loop 156 through the transfer loop side 166 of thermal storage apparatus 152 in direct contact with the phase change material 155 in thermal storage apparatus 152. The transfer medium flowing through the thermal storage apparatus 152 absorbs heat flux from storage and carries it to radiator 221 located within the confines of the interior space of the vehicle to be conditioned. Fan 174 creates an airflow across the transfer coil 222 to draw the high temperature thermal effect out of the transfer medium in a heat exchange with ambient air from the vehicle interior space. The transfer medium cycles back to the expansion tank 148 and pump 150 to continue its circulation. In the cooling configuration, the refrigerant loop side 168 of the thermal storage apparatus 152 is plumbed in parallel to the existing liquid refrigerant line 144. Valve 160 is closed to isolate the transfer loop 156 from the engine coolant system 116. In thermal energy storage system 112, the refrigerant loop side 118 is located in direct contact with the single phase change material 155 within thermal storage apparatus 152.

Upon the cooling charge cycle being completed, the cooling capacity stored in thermal storage apparatus 152 can be recovered by initiating transfer medium flow through the closed transfer loop 156 as disclosed above for the heating discharge cycle. The flow of transfer medium through pump 150 and into the transfer loop side 156 of thermal storage apparatus 152 provides a heat exchange interface with the cooled PCM 155 to lower the temperature of the transfer medium prior to its exit and circulation to the radiator 221. This low temperature transfer medium circulates through the transfer coil 222 and is exposed to an airflow induced by fan 174. The airflow is drawn across transfer coil 222 to release the cooled thermal energy in

16 the transfer medium to the interior space of the vehicle. The transfer medium then completes its cycle through expansion tank 148 and pump 150 for continued circulation. Circulation of the coolant loop 126 through thermal storage apparatus 152 can be used to heat or cool the engine 120, battery (not shown) , and associated engine components either prior to starting or immediately upon start-up or under heavy load condition of the engine 120. Agitation in thermal storage apparatus 152 by agitator 182 may be maintained in all modes during the charge/discharge cycles to prevent temperature stratification and stagnation of the phase change material 155, as well as to improve heat transfer.

Another preferred embodiment of the present invention is illustrated in Fig. 2. A thermal energy storage system 390 shown in Fig. 2 includes thermal storage apparatus 392 having a coolant loop side 394, a refrigerant loop side 396, and an optional agitator 398. Thermal energy storage system 390 shown in Fig. 2 is similar in components and operation to thermal energy storage system 112 shown in Fig. 1 with the engine coolant used as a high temperature charging source and the refrigerant used as a low temperature charging source to a single phase change material 391 within thermal storage apparatus 392. In preferred embodiments of the present invention, the single PCM 391 used in thermal energy storage system 390 is water. The primary difference between thermal energy storage system 112 and thermal energy storage system 390 is that the heat exchange process for the thermal energy discharge in thermal energy storage system 390 utilizes a convective airflow through thermal storage apparatus 392 during the discharge cycle. A fan 400 situated adjacent to the thermal storage apparatus 392 creates the airflow through the thermal storage apparatus 392 during the discharge cycles.

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A preferred embodiment of thermal storage apparatus 392 is illustrated in Fig. 3. Thermal storage apparatus 392 further includes a first housing 393 containing the PCM 391 and a second housing 395 covering the first housing 393. In preferred embodiments, the second housing 395 is made of metal or plastic. A plastic second housing 395 is lightweight and provides an insulation barrier for the PCM 391 contained in first housing 393. The first housing 393 includes end walls 383, 385 and the second housing 395 includes end walls 402, 403, top wall 404, and side walls 405, 406. A gap 397 between the first housing 393 and the second housing 395 side walls 405, 406 and top wall 404 forms an airflow passageway 397 through which the airflow travels. In addition first and second plenums 378, 379 are situated on the ends of the thermal storage apparatus 390 with the first plenum 378 being between end wall 402 and end wall 383 and the second plenum 379 being between end wall 403 and end wall 385. The fans 400 are contained in the top of the second housing 395. The fans 400 draw airflow from the interior of the vehicle through triangular-shaped openings 399 situated at the bottom of the first housing 393. The first housing 393 has a hexagonal-shaped cross section having a bottom V-shaped cross-section 380, a top V-shaped cross-section 381, and a rectangular-shaped cross-section 382 between the top and bottom V-shaped cross-sections 380, 381. The V-shaped cross-sections 380, 381 advantageously direct airflow and provide a larger surface area for the airflow to contact the PCM-containing first housing 393. The cross-sectional shape of the first housing 393 also permits the first housing 393 to expand due to forces created during the melting or freezing of the PCM 391. In alternative embodiments of the present invention, other cross-sectional shapes may be used.

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In preferred embodiments of the present invention, the refrigerant loop side 396 includes a direct expansion coil 386 and the coolant loop side 394 includes a coolant coil 387. These coils 386, 387 are placed within the first housing 393 in direct contact with the PCM 391. The coils 386, 387 exit the first housing 393 through end wall 383. The coils 386, 387 are assembled within the first housing 393 by fixing the coils 386, 387 to end wall 383, sliding the first end 383 in direction 388 toward flange 376, and attaching end wall 383 to the flange 376. In alternative embodiments of the present invention, the coils 386, 387 may be installed by assembling the first housing 393 except for the top V-shaped cross-section 381, placing the coils 386, 387 within the first housing 393, and then welding the top V-shaped cross-section 381 onto the rectangular-shaped cross-section 382.

The end walls 383, 385 include apertures 389. Similar apertures 401 are situated on the end walls 402, 403 of second housing 395 so that when the second housing 395 is placed over the first housing 393 the apertures 389, 401 line up to allow air flow into the first and second plenums 378, 379 in direction 408. A grid of open passageways 377 is formed in end walls 402, 403 to also allow air flow into plenums 378, 379. Regardless of the discharge mode, a convective airflow is created through the airflow passageway 397 of thermal storage apparatus 392 by the fans 400 to transfer the energy from the phase change material 391 within thermal storage apparatus 392 to the passing airflow. The inlet airflow with the ambient interior vehicle conditions enters the thermal storage apparatus 392 through apertures 389, 401 and passageways 377 and flows through the plenums into the triangular-shaped openings 399. The air flow continues through the air flow passageway 397 where it is in direct contact with the first housing 393 for heat

19 exchange with the PCM 391 and discharged back into the interior space of the vehicle in direction 409 to provide temperature maintenance. The interior and exterior surfaces of the first housing 393 may be constructed to enhance heat transfer and turbulize airflow with fins, corrugations, structural ribbing, etc.

Spaced apart vents 407 are situated on the top V- shaped section 381. These vents 407 relieve pressure created in the first housing 393 due to the expansion of the PCM as it changes phases and temperatures. The vents 407 are spaced apart so that pressure can be relieved even when the thermal storage apparatus 392 is tilted. In addition, the PCM 391 can be loaded into the first housing 393 through the vents 407. The vents 407 can be connected together to have a single vent (not shown) to prevent the

PCM 391 from spilling out of the first housing 393 when the thermal storage apparatus 392 is tilted.

Preferred embodiments of portions of the controller 184 are shown in Figs. 4-11. A first embodiment shown in Figs. 4-6 includes a first charging control circuit 610 that is part of controller 184. Charging control circuit 610 permits the vehicle occupant to operate the air conditioning system 118 to cool the interior of the vehicle or to charge the thermal energy storage system 112. Charging control circuit 610 includes an air conditioning switch 612, thermal storage charging switch 614, relay 616 having a normally closed contact 618 and normally open contact 620, solenoid valves 138 controlling refrigerant flow to the evaporator 140, 178 controlling refrigerant flow to the thermal energy storage system 112, and 160 controlling coolant flow to the thermal energy storage system 112, and an arrangement of conventional high pressure compressor 132 outlet, conventional low pressure compressor 132 inlet, and conventional low temperature evaporator 140 safety switches 628. The operation of the

20 first charging circuit 610 has three different modes as follows.

The first mode of operation for charging control circuit 610 is shown in Fig. 4 where, during vehicle engine 120 operation, the air conditioning system 118 cools the vehicle and thermal energy storage system 112 does not charge the phase change material with heating or cooling capacity. In this mode of operation, the air conditioner switch 612 is in an ON position and the thermal storage charging switch 614 is in an OFF position. Current flows through the safety switches 628 to energize a conventional magnetic clutch 630 which starts the refrigeration system compressor 132. The current also energizes solenoid valve 138 to allow refrigerant to flow to the evaporator 140 to cool the interior of the vehicle while the engine 120 is operating. Because normally open contact 620 is open, solenoid valve 178 is not energized and thus refrigerant does not flow to the thermal energy storage system 112. In this mode of operation, the air conditioning system 118 operates in its normal mode to cool the interior of the vehicle while the vehicle engine 120 is operating. If any of the safety switches in arrangement 628 are off, the magnetic clutch 630 is de-energized and thus the compressor 132 is also off. The second mode of operation for charging control circuit 610 is illustrated in Fig. 5 where, during vehicle engine 120 operation, the thermal energy storage system 112 stores low temperature thermal energy and the air conditioning system 118 does not cool the vehicle interior. In this mode of operation, the thermal storage charging switch 614 is in the cool position and air conditioning switch 612 may either be in the OFF or ON position. The electrical current from thermal storage charging switch 614 energizes the relay 616 to open normally closed contact 618 and close normally open contact 620. The current flows

21 through the contact 620 to energize the magnetic clutch 630 as long as the safety switches of the manifold 628 are in their normal operating positions. The activation of magnetic clutch 630 initiates operation of the refrigeration compressor 132. The current in this mode of operation energizes solenoid valve 178 permitting refrigerant flow to the thermal energy storage system 112. Solenoid valve 138 is not activated because normally closed contact 618 is open. In this mode of operation, the air conditioning system 118 is only used to charge the thermal energy storage system 112.

The third mode of operation for charging control circuit 610 is shown in Fig. 6 where, during vehicle engine 120 operation, the thermal energy storage system 112 stores high temperature thermal energy and the air conditioning system 118 may be either on or off. In this mode of operation, the thermal storage charging switch 614 is in the hot position and the air conditioning switch 612 may either be in the ON or OFF position. In this mode of operation, solenoid valve 160 is energized to permit engine coolant to flow into the thermal energy storage system 112 to provide a high temperature thermal energy source. If the air conditioning switch 612 is in the ON position, the air conditioning system 118 operates to cool the interior of the vehicle while the engine 120 is operating. The operation of the air conditioning system 118 does not affect the ability of the heating charge cycle occurring simultaneously in the thermal energy storage system 112.

A second embodiment of a charging control circuit 640 of controller 184 is shown in Figs. 7-10. Charging control circuit 640 includes the air conditioning switch 612, thermal storage charging switch 614, solenoid valves 138, 160, and 178, and arrangement 628 containing high pressure compressor 132 outlet, low pressure compressor 132 inlet, and low temperature evaporator 140 safety switches.

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The charging control circuit 640 further includes relay 642 having contacts 644, 646, 648, and 650, relay 652 having contacts 654, 656, timer 658, and a potentiometer 659 connected to the timer 658. Charging control circuit 640 operates in four different modes as follows.

The first mode of operation for charging control circuit 640 is shown in Fig. 7 where, during vehicle engine 120 operation, the thermal energy storage system 112 does not store either high or low temperature thermal energy and the air conditioning system 118 cools the vehicle interior. In this mode of operation, the air conditioning switch 612 is in the ON position and the thermal storage charging switch 614 is in the OFF position. Current flows through and energizes relay 642 to close normally open contacts 644, 646 and open normally closed contacts 648, 650.

Because relay 652 is not energized, normally closed contact 654 remains closed. The current flows through the closed contacts 644 and 654 to energize and open solenoid valve 138 permitting refrigerant to flow to the evaporator 140 of the air conditioning refrigerant system 118. Current also flows to energize the magnetic clutch 630 to start the air conditioning compressor 132 if all safety switches 628 are in the operation positions. If any of the safety switches in arrangement 628 are off, the magnetic clutch 630 de- energizes and shuts down the compressor 132. In this mode of operation with the thermal storage charging switch 614 in the OFF position, solenoid valves 160, 178 are de- energized which prevents either refrigerant or coolant from reaching the thermal energy storage system 112. The second mode of operation for charging control circuit 640 is illustrated in Fig. 8 where, during vehicle engine 120 operation, the thermal energy storage system 112 stores low temperature thermal energy and the air conditioning system 118 cools the vehicle interior. In this mode of operation, air conditioning switch 612 is in

23 the ON position and the thermal storage charging switch 614 is in the cool position. Current travels through and energizes relays 642 and 652. Contacts 648, 650, and 654 are open and contacts 644, 646, and 656 are closed. The magnetic clutch 630 is energized to activate refrigerant compressor 132 if the safety switches in manifold 628 are in the normal operation position.

Current flows through the cool contact of thermal storage charging switch 614 and contact 646 to reach timer 658. The timer 658 cycles through a continuous sequence of opening solenoid valve 138 and closing solenoid valve 178 to permit refrigerant to flow to the evaporator coil 140 and closing solenoid valve 138 and opening solenoid valve 178 to permit refrigerant to flow to the thermal energy storage system 112 to provide a low temperature thermal energy charge to the system 112. In preferred embodiments of the present invention, the timer 658 operates to permit refrigerant to flow to the evaporator coil 140 for 120 seconds and then permits refrigerant to flow to the thermal energy storage system 112 for 30 seconds. This 120 second/30 second timing interval continues as long as the air conditioning switch 612 is in the ON position and the thermal storage charging switch 614 is in the cool position. The potentiometer 659 operates to change the timing interval.

The third mode of operation for charge control circuit 640 is shown in Fig. 9 where, during vehicle engine 120 operation, the thermal energy storage system 112 stores low temperature thermal energy and the air conditioning system 118 does not cool the vehicle interior. In this mode of operation, the air conditioner switch 612 is in the OFF position and the thermal storage charging switch 614 is in the cool position. Relay 642 is not energized and relay 652 is energized, so contacts 644, 646, and 654 are open and contacts 648, 650, and 656 are closed. Magnetic clutch

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630 is energized to activate the refrigerant compressor 132 if the safety switches 628 are in the operational position. Because contacts 646 and 654 are open, there is no current to solenoid valve 138 or to timer 658. Solenoid valve 178 is the only solenoid valve opened, permitting continuous refrigerant flow to the thermal energy storage system 112.

The fourth mode of operation for charging control circuit 640 is illustrated in Fig. 10 where, during vehicle engine 120 operation, the thermal energy storage system 112 stores high temperature thermal energy and the air conditioning system may either cool or not cool the vehicle interior. In this mode of operation, the air conditioning switch 612 may be in either the ON or OFF position and the thermal storage charging switch 614 is in the hot position. Solenoid valve 160 is energized and opened to provide a path for coolant to flow to the thermal energy storage system 112 to provide a high temperature thermal energy source. Air conditioning system 118 operates simultaneously with the high temperature charging of the thermal energy storage system 112 if the air conditioning switch 612 is in the ON position.

Charging control circuit 640 permits the vehicle operator to charge the thermal energy storage system with high or low temperature thermal energy while simultaneously running the heating system 116 or cooling system 118 to heat or cool the interior of the vehicle.

Discharging control circuit 670 portion of controller 184 is shown in Fig. 11. Discharging control circuit 670 includes an ignition control circuit 672, a fan control circuit 674, and a thermostat control circuit 676 for thermostat 678 operation. Discharging control circuit 670 further includes fans 174, relay 680 having contact 682, relay 684 having contacts 686, 688, and a discharge switch 690.

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When the vehicle engine 120 is operating, ignition control circuit 672 energizes relay 680 to open contact 682 and de-energize the fans' 174 power supply to ensure there is no air flow past a thermal storage apparatus when the engine 120 is operating. After the engine 120 is turned off, the vehicle operator can select a discharge switch 690 position of OFF, hot, or cool. When the discharge switch 690 is in the OFF position, the fans 174 do not operate. All embodiments of the present invention may include a control system to permit low temperature thermal energy stored in a thermal energy storage system to supplement a radiator in a coolant system to prevent an engine 120 from overheating during extreme load conditions. For example, this may be necessary when the vehicle is traveling uphill on a hot day. This same control system could operate to warm-up the vehicle engine 120, battery, and engine component before engine 120 start-up.

All embodiments of the present invention may be used in a variety of environments including electric vehicles, hybrid electric vehicles, vehicles with conventional combustion engines, and buildings. Further, all embodiments of the present invention can be hot or cool charged by connecting them to boilers, furnaces, electric sources, heating and cooling systems, building power grids, etc.

All phase change materials for all embodiments may exhibit sensible and/or latent heat capabilities, as well as phase change characteristics, depending upon transition temperatures and system operating temperature ranges.

It will be apparent to those skilled in the art that various changes and modifications can be substituted for those parts of the system described herein. For example, thermal storage medium and transfer fluids, other

26 than those specifically described herein, can be advantageously used. Further, various substitutes for valves and pumps and/or additional valves or pumps illustrated in the drawings can be employed in accordance with the invention. Furthermore, multiple thermal storage apparatus and/or systems may be added to the vehicle in accordance with the present invention.

All of the illustrated embodiments denote a controller 184. This controller 184 controls the illustrated pumps, fans, solenoid valves, and agitators in all illustrated embodiments.

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of the invention as described and defined in the following claims.